Efficiently installable and durable embedment tile for producing tactilely-detectable surfaces

ABSTRACT

Disclosed is an embedment tile for producing a tactilely detectable surface in concrete or asphalt, comprising a tile member substantially planar in form, having a pattern of upwardly extending projections on its upper surface forming a tactilely detectable pattern (e.g., warning, way-finder, decorative or other), and, two or more cross beams on the lower surface of the tile member, with hollow channels and end openings, and optionally also with several apertures enabling flow of air and concrete or asphalt in and around the cross beams to facilitate rapid installation. The embedment tile may further consist of support members which project down further than the cross beams and function for support and to interlock the embedment tile to the concrete or asphalt once they set and harden. Methods for installing the tile are also disclosed.

CROSS-REFERENCES

This application is entitled to the benefit of U.S. Provisional Patent Application Ser. No. 60/505,794, filed 2003 Sep. 25. Applicant(s) requests that Disclosure Document no. 536197, filed at U.S. Patent and Trademark Office on 2003 AUG 11, be associated with this application.

BACKGROUND

The Department of Justice (DOJ), the lead agency that oversees the Americans with Disabilities Act (ADA), has mandated that many municipalities and other governmental bodies comply with certain regulations regarding accessibility. One such regulation deals with accessibility on walkways in public right of ways. In brief, it requires that surfaces of those walkways enable tactile detection by visually impaired persons.

One of the primary ways of providing the ability to detect proximity to hazardous locations (e.g., roadways, railroad crossings, etc.) is by modifying the surface texture of the walkways. Tactilely detectable warnings are distinctive surface patterns of domes detectable by cane or underfoot, and are used to alert people with vision impairments of their approach to streets and hazardous drop-offs. The ADA Accessibility Guidelines (ADAAG) require these warnings on the surface of curb ramps, which remove a tactile cue otherwise provided by curb faces, and at other areas where pedestrian ways blend with vehicular ways. They are also required along the edges of boarding platforms in transit facilities and at the perimeter of reflecting pools.

Complying with the federal mandate is requiring the expenditure of much time and money by the municipalities to modify the surface textures of their sidewalks and other walkways. The need for a tactile warning device that is cost effective is essential to enable municipalities to comply with the ADA unfunded mandates. It is also needed by non-governmental entities, such as land developers, railroad companies and others who likewise need to provide tactile-detectable surfaces at curb ramps, platforms and the like.

Some embedded tile devices currently exist for providing tactilely detectable warning surfaces for the visually impaired in concrete walkways. Once embedded in concrete or asphalt, these devices form a truncated dome portion of the surface that is detectable to people on foot.

However, most of these devices are made out of plastic and are flimsy, being subject to ultraviolet light damage, deterioration and cracking in short periods of time. Also, inherent to the truncated dome design is the exposure of domes to severe impacts by snowplow equipment, particularly snowplow blades and end-loader buckets. Domes made of plastic tend to be sheared off, nicked or cracked when snowplows hit them. Once damaged, repair requires that entire plastic embedded tiles be removed and replaced. The fact that plastic embedded tile devices are easily damaged results in high long-term costs to maintaining truncated dome surfaces when they are employed. Yet, current manufactures of plastic embedded tile devices either do not warrant the devices or warrant them for no more than five years. Public entities cannot afford to replace truncated dome devices every five years—nor every ten to fifteen years for that matter. A more durable device is needed.

Information somewhat relevant to attempts to address these problems can be found in U.S. Pat. Nos. 5,775,835 to Szekely; 6,449,790 to Szekely; 6,715,956 TO Weber et al.; and, U.S. patent Application Publication US 2004/0042850 to Provenzano, III. However, each one of these references suffers from one or more of the following disadvantages: (1) they do not enable embedment of a tile in materials such as concrete or asphalt; (2) they lack means for securely interlocking a tile with the concrete or asphalt; (3) they result in build-up of concrete or asphalt around the edges of the tile when inserted, resulting in longer installation times due to the need for removal of the buildup prior to finishing; (4) the tiles are not designed to efficiently move air and concrete or asphalt to enable the rapid sinking of the tile, and without the need for applying weights to prevent the tile from floating while the concrete or asphalt sets; and, (5) the tiles are not made of materials that stand up to the cracking and sheering effects of snowplows or other heavy equipment, thus resulting in high maintenance costs over time.

For the foregoing reasons there is a need for an embedment tile device that is designed to be both easily installable to minimize installation time and cost, and durable to minimize long-term maintenance costs and to reliably provide tactilely detectable surfaces.

SUMMARY

The present invention is directed to an embedment tile and method that satisfy this need for a device that is designed to be both easily installable to minimize installation time and cost, and durable to minimize long-term maintenance costs and to reliably provide tactilely detectable warning surfaces.

One version of the embedment tile for embedment in concrete or asphalt, comprises a tile member substantially planar in form, having an upper surface and a lower surface and two or more sides defining side edges, the upper surface having several projections extending upward there from in a tactilely detectable pattern; and, two or more cross beams attached to the lower surface of the tile member and projecting downward a distance there from, the distance defining a depth of the cross beams, each cross beam comprising a sidewall having two opposing ends which define a length there between, the sidewall being shaped so as to define a hollow channel extending the length and an opening at each end, the channel being in communication with an exterior via the openings, whereby air and the concrete or asphalt are displaced around and into the openings of the cross beams and toward the lower surface and two or more sides of the tile member as the embedment tile is embedded therein.

In another version, the two or more cross beams further consist of two or more apertures to enable air and concrete or asphalt to flow into the central hollow channel facilitating insertion of the embedment tile therein and providing further interlocking between the tile and the set concrete or asphalt.

In yet another version, the embedment tile further consists of support members. Support members are attached to the lower surface of the tile member and projecting downward a distance there from, the distance defining a depth of the support member, the depth of the support member being greater than that of the two or more cross beams and comprising a sidewall having two opposing ends which define a length there between, the sidewall being shaped so as to define a hollow channel extending the length and an opening at each end, the channel being in communication with the exterior at each end via the openings, whereby the concrete is displaced around and into the openings of the support members as the embedment tile is lowered into the concrete. The support members may also function to support the tile member during installation.

In other versions, the upper surface of the tile member may be skid-resistant, all or a portion of the embedment tile may be manufactured out of stainless steel, and/or its projections may consist of a surface of truncated domes distributed in a warning pattern compliant with the Americans with Disabilities Act Accessibility Guidelines.

In other versions, methods for making a tactilely detectable surface using the embedment tile as described above are disclosed.

Several objects and advantages of the present invention are:

-   -   providing an embedment tile with cross beams on its lower         surface designed to optimize air release and concrete movement         upon embedment in concrete and to move concrete into and around         the cross beams and toward the lower surface and sides as the         embedment tile is embedded therein to enable rapid, efficient         and quality installations;     -   means for providing tactilely detectable warning surfaces (or         other surface patterns such as way-finder, decorative and the         like) that are both efficiently installed and durable to enable         entities to comply with ADA Accessibility Guidelines, or other         requirements, rapidly and cost-effectively;     -   means for providing tactilely detectable surfaces in materials         such as concrete and asphalt efficiently and reliably so as to         save installation time and labor costs;     -   means for providing tactilely detectable surfaces in materials         such as concrete and asphalt durably so as to minimize the need         for replacement and thereby, the long-term costs of maintenance,         by providing embedment tiles that last at least as long as the         surrounding materials;     -   means for providing embedment tiles that are reusable in order         to conserve materials and to minimize replacement costs; and,     -   means for providing embedment tiles with improved recyclability         so as to maximally conserve environmental resources.

The reader is advised that this summary is not meant to be exhaustive. Further features, aspects, and advantages of the present invention will become better understood with reference to the following description, accompanying drawings and appended claims.

BRIEF DESCRIPTION OF DRAWINGS

For a better understanding of the present invention, reference may be made to the accompanying drawings, in which:

FIG. 1 a, shows a top perspective view of a version of the embedment tile;

FIG. 1 b, shows a bottom perspective view of the version of the embedment tile depicted in FIG. 1 a;

FIG. 2 a, shows a top view detail of the tile member depicted in the embedment tile of FIG. 1 a;

FIG. 2 b, shows the cross section indicated in FIG. 2 a, detailing a projection and an optional edge flange of the tile member;

FIG. 2 c, shows a side view (both sides being alike) of the tile member depicted in FIG. 2 a;

FIG. 2 d, shows an end view (both ends being alike) of the tile member depicted in FIG. 2 a;

FIG. 3, shows a bottom view of the embedment tile depicted in FIGS. 1 a and 1 b;

FIG. 4 a, shows a side view of the embedment tile depicted in FIGS. 1 a and 1 b;

FIG. 4 b, shows the detail “A” of FIG. 4 a, enlarged to show apertures and the location of a cross beam perpendicularly to another aligned to allow optional insertion of reinforcement bars there through;

FIG. 4 c, shows an end view of the embedment tile depicted in FIGS. 1 a and 1 b;

FIGS. 5 a to 5 c, show side view details of versions of cross beams which vary in length and in number of apertures;

FIG. 6, shows cross-sectional views of versions of the cross beams which vary in way in which they are attached to the lower surface of the tile member;

FIG. 7, shows cross-sectional views of versions of the cross beams which vary in shape of the side wall;

FIGS. 8 a to 8 c, show a cross sectional view through an embedment tile showing one cross beam with apertures as it is lowered into a matrix of concrete or asphalt; arrows in matrix indicate direction of flow of concrete or asphalt as it is displaced by the cross beam and as it flows into the hollow channel of the cross beam via its apertures;

FIG. 9, shows a side view and several end views of a support member; and,

FIGS. 10 a to 10 c, show samples of tile members varying in number of sides from 2-sided to 3- and 4-sided, respectively.

DESCRIPTION

Referring now specifically to the figures, in which identical or similar parts are designated by the same reference numerals throughout, a detailed description of the present invention is given. It should be understood that the following detailed description relates to the best presently known embodiment(s) of the invention. However, the present invention can assume numerous other embodiments, as will become apparent to those skilled in the art, without departing from the appended claims. For example, though the present embedment tile is described relative to embedment in concrete, it may also be embedded in other materials such as asphalt. Also, though the tactilely detectable surface of the embedment tile is described as producing a warning pattern compliant with ADA Accessibility Guidelines, any pattern may be produced, including way-finder patterns, purely decorative patterns, emblematic patterns or patterns of other sorts.

It should also be understood that, while the methods disclosed herein may be described and shown with reference to particular steps performed in a particular order, these steps may be combined, sub-divided, or re-ordered to form an equivalent method without departing from the teachings of the present invention. Accordingly, unless specifically indicated herein, the order and grouping of the steps is not a limitation of the present invention.

Detailed Description—Embedment Tile

Referring to FIG. 1, one version of the embedment tile device of the present invention is depicted. This version of the embedment tile device 100 is designed for embedment in concrete walkways to bring them into compliance with the Americans with Disabilities Act Accessibility Guidelines (ADAAG) by producing tactilely detectable warning surfaces. Though the accompanying drawings and following description relate to use of the embedment tile 100 for creating tactilely detectible warning surfaces in concrete, the reader is reminded that the tiles 100 may be used to produce other surface patterns in a variety of places other than walkways specifically, and in a variety of materials other than concrete, including asphalt.

The embedment tile 100 comprises a tile member 200 and two or more cross beams 300. It may further comprise two or more support members 400.

The tile member 200 is substantially planar in form, having an upper surface and a lower surface and two or more sides defining side edges. As depicted in most of the figures, the tile member 200 has 4 side edges. However, the same design can be constructed to meet the needs of a user for different shapes, including, for example, skewed curb ramp approaches, blended sidewalk approaches, sides of curb ramp approaches and the like where the number of side edges may vary (see FIGS. 10 a-10 c for examples of 2-, 3-, and 4-sided versions, respectively).

Referring to FIG. 1 a, the tile member 200's upper surface comprises many projections 210 extending upward from the surface. As depicted, these projections 210 are distributed in a tactilely detectable warning pattern. As shown in FIG. 1 a, the projections 210 are shaped like truncated domes and are distributed in a matrix of rows and columns in conformance with the ADAAG. As the ADA guidelines evolve over time or as users require conformance with other guidelines, the projections 210 may be altered in form, size, distribution pattern and spacing to meet those new requirements. For example, users may require the projections 210 to form a way-finder pattern, decorative design or some other pattern.

Referring to FIGS. 2 a to 2 d, detailed views of the version of the tile member 200 depicted in FIG. 1 a are provided. A top view is provided in FIG. 2 a, side view in FIG. 2 c and an end view in FIG. 2 d. FIG. 2 b shows a cross-sectional view through one of the truncated dome projections 210 and one edge of the tile member 200 (defined as section B-B in FIG. 2 a).

Note that in FIGS. 2 b to 2 d, a vertical flange 220 is shown extending vertically downward from each edge of the tile member 200. Vertical flanges 220 are optional. When present, however, the vertical flanges 220 function to further stabilize the tile member 200 and enable the easy connection of additional embedment tiles 100 as may be necessary to extend or expand surface projection areas by bolting them together at the flanges 220 (note that bolt holes 222 are shown in the vertical flanges 220 as depicted in FIGS. 1 a-1 b, 2 c-2 d, 4 a-4 c).

As mentioned above, the size of the tile member 200 as well as its shape and number of sides may vary depending on a user's needs. By way of example, in one version as depicted in FIGS. 1 a, 1 b, and 2 a-2 d, the tile member is about 24.0 inches (61 cm) wide by 48.0 inches (122 cm) long. Many other sizes are possible.

The upper surface of the tile member 200 may further be conditioned or surfaced so as to provide skid-resistance. For example, if the tile member 200 is made of a metal material, such as stainless steel, the upper surface might be etched or otherwise surfaced to provide skid-resistance. In addition or alternatively, the upper surface may be coated with a material to improve or provide its skid-resistant quality. Color for improved visual contrast of the embedment tile 100 may further be provided by treatment of the embedment tile 100's material itself, and/or by coating it with a colorant. A variety of techniques may be used to impart the embedment tile 100 with long-lasting color contrasting and skid resistance.

The embedment tile 100 further comprises two or more cross beams 300 that are attached to and project downward a distance from the lower surface of the tile member 200, the distance defining a depth 360 of the cross beams 300 (see FIGS. 1 b and 3, in which 5 cross beams 300 are shown). Each cross beam 300 consists of a sidewall 310 having two opposing ends which define a length there between. The sidewall 310 is shaped so as to define a hollow channel 340 extending the length and an opening 320 at each end. The channel is in communication with an exterior at each end via the openings.

The depth of the sidewall 310 may vary. As illustrated in the accompanying drawings (FIGS. 1 b, 4 a-4 c), the depth 360 is about 2.0 inches (5.1 cm). Generally the depth 360 will be 1.0 inches (2.5 cm) or more. However, many other depths 360 are possible. Likewise, lengths may vary.

The cross beams 300 may be distributed on the lower surface of the tile member 200 in various ways. As depicted in FIG. 3, two longer cross beams 300 (detailed in FIG. 5 c) are located length wise toward the outer edges of the lower surface of the tile member 200. Two cross beams 300 of shorter length (detailed in FIG. 5 a) are located at opposite ends of the lower surface of the tile member 200 so as to span the distance between and to rest perpendicularly to the two longer beams 300. A fifth cross beam 200 (detailed in FIG. 5 b) is located lengthwise down the middle of the lower surface of the tile member 200 in parallel to and midway between the two longer cross beams 200, and spanning the distance between the two short cross beams 200 running perpendicular to them. Other orientations (such as diagonal) and numbers of cross beams 300 may be employed also.

Likewise, the shaping of the sidewall 310 may vary (see FIG. 7 for cross-sectional views). The sidewalls 310 of the cross beams 300 may be shaped so that the cross beams are substantially V-shaped in cross section as in the version depicted in FIGS. 1 b, 4 b-4 c, 5 a-5 c. The V-shape functions well to enable the cross beams 300 to embed efficiently in wet concrete or asphalt, acting to move concrete or asphalt into and around the cross beams 300 to enable insertion (as shown in FIGS. 8 a to 8 c). However, as mentioned previously, the sidewall 310 may be formed to other cross-sectional shapes as well that function likewise such as U-shaped, round, square or otherwise (see FIG. 7).

As seen in FIG. 6, the way in which the cross beam 300 is attached to the lower surface of the tile member 200 may vary. For example, a cross beam 300 may be attached by its two side edges 312, one side edge 312 and a portion of the sidewall 310 adjacent to the opposing side edge 312, by portions of the sidewall 310 adjacent to each side edge 312, or in some other way.

The sidewall 310 of the cross beams 300 may further consist of two or more apertures 330 distributed along its length. The channel 340 is in further communication with the exterior via the apertures 300, further improving air release and concrete movement into and around the cross beams 300 as the embedment tile 100 is lowered into the surface of the wet concrete.

The apertures 320 may also vary in shape such as round (as depicted in the figures), saw-toothed, triangular, rectangular and so forth. The number and size of the apertures 310 will vary with the depth and length of the cross beam 300. Several cross beams 300 of varying lengths are depicted in FIGS. 5 a-5 c in side view. In these versions, as length increases, so do the number of apertures 310, though the number and distribution of apertures 310 may vary and are not necessarily proportional to length of the cross beam 300.

The apertures 320 function to improve the amount of concrete or asphalt that intrudes into the hollow channels 340, and thus the interlocking function of the cross beams 300. The apertures 320 also serve to enable air to escape as concrete or asphalt enters the channels 340 (see, e.g., FIGS. 8 a to 8 c). By enabling air to escape and concrete or asphalt to move into place more smoothly, the installation of the embedment tile 100 may proceed more quickly. Also, allowing air to escape enables the embedment tile 100 to remain in place at the desired grade without requiring weights during installation (when lowered into wet concrete). This too improves the efficiency of installation. Also, because some of the wet concrete or asphalt moves into the hollow channels 340 via the apertures 320, improved interlocking occurs between the embedment tile 100 and the dry concrete or asphalt walkway.

As can be seen from the above, cross beams 300 function to stabilize the tile member 200 and are also designed to function to provide good air release and concrete movement by displacing air and the concrete into (via the end openings 320 and apertures 330) and around the cross beams 300 toward the lower surface and sides of the tile member 200 as the tile 100 is lowered into wet concrete, thus easing the embedment tile 100 down into the concrete and thereby facilitating rapid embedment of the tile 100 (see FIGS. 8 a to 8 c). In versions of the tile member 200 where the projections 210 on the upper surface are accompanied by matching indentations on the lower surface below (as illustrated in FIGS. 1 b, 2 b, 3), the cross beams 300 also function to move the concrete into the indentations, eliminating voids therein and thereby further fortifying the projections 210 above against cracking and breaking from heavy equipment.

Once the concrete sets and hardens, the portions of same which flowed into the channels 340 of the cross beams 300 (via the end openings 320 and apertures 330) function to interlock the tile 100 with the hardened concrete.

To further improve interlocking, reinforced steel bars (reinforcement bars or, re-bars, L-bars, tie-bars and the like) may optionally be employed. These are sometimes desired by designers to assist with unusual applications. The re-bars may be inserted through or into the cross beam 300 and/or support beam 400 (see below) channels 340/440, and/or the apertures 330. In some versions of the cross beams 300, additional re-bar apertures 332 may be provided to enable more options for insertion of re-bars. Referring to FIG. 4 b, a version of cross beams 300 are shown with a re-bar aperture 332 located in one cross beam 300 so as to allow a reinforcement bar to be inserted at least partly there through and extend through an adjacent and perpendicularly oriented cross beam 300's hollow channel 340. Many variations on orientation of apertures 330/332 may be employed according to the needs of the user.

In some applications, tie-bars may be used to tie the tiles 100 to the surrounding concrete, particularly for tying narrow strips of concrete to the tile 100 and to keep tooled or untooled cracks (joints) from moving or offsetting. In general, tie-bars would extend through tooled in concrete joints in the sidewalk. The use of reinforced steel bars further stabilizes the embedment tile 100 and strengthens the interlocking between it and the concrete. Reinforcement bars may further aid in joining adjacent embedment tiles 100 to form larger areas of surface projections 210. Reinforcement bars may still further function in securing the embedment tile 100 in place during installation (see Method section below).

The embedment tile 100 may further consist of two or more support members 400 (see FIGS. 1 b, 3, 4 a, 4 c, 9) which function as support of the tile member 200 during installation. Support members 400 are attached to and project downward from the lower surface of the tile member 200 for a distance defining a depth 460 greater than the depth 360 of the two or more cross beams 300. The support members 400 may be two-dimensional and affixed perpendicularly in orientation to the lower surface of the tile member 200. Alternatively, the support members 400 may be three-dimensional constructs similar to the cross beams 300, but shorter in length as depicted in the figures referenced above.

In their three-dimensional version, support members 400 consist of a sidewall 410 having two opposing ends which define a length there between. The sidewall 410 is shaped so as to define a hollow channel 440 extending the length and an opening 420 at each end, the channel being in communication with the exterior via the openings 420. In this way concrete is displaced around and into the openings 420 as the embedment tile 100 is embedded in the concrete (similarly to how the cross beams 300 function and as depicted in FIGS. 8 a to 8 c). Thus an interlocking function is provided by the support members 400 once the concrete hardens in and around them, securing the tile in the concrete matrix when the concrete hardens.

Note that the sidewall 410 may assume various shapes in cross section similarly to those of the cross beams 300. Referring to FIG. 9, the sidewall 410 in a substantially V-format is shown. As can be seen, it may be bent to open the channel 440 to the exterior along its length as in the two lower cross-sectional views. These more open versions may facilitate bending in circumstances where users must fit the embedment tiles 100 in odd places and positions relative to other objects, affording the user flexibility in how they may manipulate the support members 400.

As mentioned above, the support members 400 project downward from the lower surface of the tile member 200 for a depth 460 greater than the depth 360 of the two or more cross beams 300. By so doing, the support members 400 may further function to hold the tile member 200 at the appropriate level above the sub-layer of the walkway (e.g. at the surface height of the walkway) during concrete pouring operations thereby providing an area for the concrete or asphalt to flow around and underneath (see descriptions in method section of this alternative method of installation). This enables a user to install the tile 100 quickly into fresh concrete and to work from the surface of the tile member 200 to finish around the embedment tile 100 as necessary. Concrete finishing operations can continue without delay when using the embedment tile 100 with support members 400 attached.

The embedment tile 100 may be made in whole or in part, out of a variety of materials. Stainless steel has advantages of strength, durability and recyclability. However, the embedment tile 100 may be made out of other hard, durable materials such as galvanized steel, other metals, hard plastics, fiber reinforced plastics, resins and the like. As technology evolves, other types of metals, plastics, resins and the like may be developed that may be used to provide the durability needed in the tile member 200 and its projections 210, among other parts of the embedment tile 100.

Some advantages of using stainless steel is that it is recyclable, thus conserving resources, and highly durable. Stainless steel will not be damaged by ultraviolet light, will not crack and will withstand heavy vehicle loading, e.g., snowplow equipment (including snow plows, end loaders, skid loaders) and heavy truck traffic across the domed area of the walkway. Unlike plastic dome projections 210 which experience all of the preceding types of damage, steel dome projections 210 will not sheer off when hit by snowplows and the like and will last as long as the concrete around them does. Maintenance of stainless steel embedment tiles 100 is, therefore, largely limited to periodically resurfacing an optional topcoat as necessary to maintain color contrast and skid resistance. The frequency and cost of maintenance over the long-term is thus minimized. The high durability of steel embedment tiles 100 ensures that the tactile-detectible surface is compliant with ADA requirements and that the surface is therefore, in condition to safely warn the blind and other users.

In those cases where ramped walkways, including the tactilely-detectable surface areas are removed from time to time for utility repairs or other necessary work, the embedment tile 100 can be removed for re-use again at the same site or other locations. This further reduces the costs of using the stainless steel version of the embedment tiles 100.

Detailed Description—Method

The various versions of the embedment tile 100 of the present invention may be embedded in fresh concrete or asphalt in various ways. Following are descriptions of two basic methods, though others may be employed. The descriptions specify how to embed the tile 100 in fresh concrete. However, the basic methodology may be applied to other materials such as fresh asphalt.

The design of the embedment tile 100 enables installation to proceed easily and rapidly. For example, certain versions of the embedment tile 100 require only about 1 minute to install in concrete.

In general, the embedment tile 100 is either (a) embedded into already poured wet concrete or (b) is secured in place before the concrete is poured to fill in the walkway or other surface areas around and underneath the embedment tile 100. Once installed, the embedment tile 100 provides a pattern of projections 210 on its upper surface that remains exposed to pedestrian traffic once the concrete sets and hardens to provide a surface that is tactilely-detectable to pedestrians.

One version of the method for producing a tactilely detectable surface in concrete comprises providing a version of the embedment tile 100 described above for embedment in wet concrete. A user installs the embedment tile 100 by (a) lowering the embedment tile 100 into the concrete; and, (b) positioning the upper surface of the tile member 200 relative to a surface of the surrounding concrete as desired and so that the upper surface's tactilely-detectable pattern of projections 210 is exposed. A user may optionally work from the surface of embedment tile 100, finishing (and optionally also edging) around the two or more edges of the embedment tile 100. The concrete is then allowed to set and interlocking to occur between the embedment tile 100 and the hardened concrete.

Another version of the method for producing a tactilely detectable surface in concrete also comprises providing a version of the embedment tile 100 described above prior to pouring wet concrete. In this version however, a user installs the embedment tile 100 by (a) securing the embedment tile in place relative to an existing sub-base or newly prepared sub-base; (b) adjusting the embedment tile 100 to meet slope or grade requirements (e.g., those set by the ADA Accessibility Guidelines or other requirements of the user); and, (c) pouring the concrete onto the sub-base in a formed area and under and around the embedment tile 100. A user may work from the surface of embedment tile 100, working the concrete under and around the embedment tile 100 and finishing (and optionally also edging) around the two or more edges of the embedment tile 100. The concrete is then allowed to set and interlocking to occur between the embedment tile 100 and the hardened concrete. This version may further comprise using a concrete vibrator to consolidate the concrete.

Securing the embedment tile 100 in place may comprise (a) anchoring the embedment tile 100 to the sub-base, or (b) suspending the tile above the sub-base.

Anchoring the embedment tile 100 will generally involve resting the embedment tile 100 on the sub-base or a portion thereof [depending on version, it may rest on the sub-base (or shims placed on the sub-base) by its cross-beams 300 or by its support members 400]. Once resting in place, one or more weights (such as sand bags, cement blocks, or the like) may be placed directly on the upper surface of the embedment tile 100. Alternatively, L-shaped reinforcement bars (or, re-bars) may be placed through or into the bottom portions of hollow channels 440 of the support members 400 (or if resting on cross-beams 300, through the bottom portions of hollow channels 340) and secured to the sub-base by pushing or tapping the reinforcement bars down into the sub-base. Likewise, other types of reinforcement bars and means for anchoring the embedment tile 100 may be employed.

Alternatively, securing the embedment tile 100 in place may consist of suspending the embedment tile 100 above the sub-base before the concrete is poured. In one version, the embedment tile 100 is suspended above the sub-base by placing L-shaped reinforcement bars (or, re-bars) into the hollow channels 340 of the cross beams 300 or aperture's 320 of cross beams 300 and securing the other ends of the reinforcement bars into the sub-base by pushing or tapping the reinforcement bars down into the sub-base. Alternatively, suspending the embedment tile 100 may be accomplished by securing a wood board or other rigid material to the upper surface of the embedment tile 100, then resting ends of the wood board on an existing portion of concrete surface (such as a walkway and back of curb and gutter) to hold the embedment tile 100 to grade. Other alternatives for suspending the embedment tile 100 may also be employed.

ADVANTAGES OF THE INVENTION

The previously described versions of the present invention have many advantages, including:

-   -   providing an embedment tile with cross beams on its lower         surface designed to optimize air release and concrete movement         upon embedment in concrete and to move concrete into and around         the cross beams and toward the lower surface and sides as the         embedment tile is embedded therein to enable rapid, efficient         and quality installations;     -   means for providing tactilely detectable warning surfaces (or         other surface patterns such as way-finder, decorative and the         like) that are both efficiently installed and durable to enable         entities to comply with ADA Accessibility Guidelines, or other         requirements, rapidly and cost-effectively;     -   means for providing tactilely detectable surfaces in materials         such as concrete and asphalt efficiently and reliably so as to         save installation time and labor costs;     -   means for providing tactilely detectable surfaces in materials         such as concrete and asphalt durably so as to minimize the need         for replacement and thereby, the long-term costs of maintenance,         by providing embedment tiles that last at least as long as the         surrounding materials;     -   means for providing embedment tiles that are reusable in order         to conserve materials and to minimize replacement costs; and,     -   means for providing embedment tiles with improved recyclability         so as to maximally conserve environmental resources.

The present invention does not require that all the advantageous features and all the advantages need to be incorporated into every embodiment thereof.

Closing

Although the present invention has been described in considerable detail with reference to certain preferred versions thereof, other versions are possible. Therefore, the spirit and scope of the appended claims should not be limited to the description of the preferred versions contained herein. 

1. An embedment tile for producing a tactilely detectable surface in concrete or asphalt, comprising: a. a tile member substantially planar in form, having an upper surface and a lower surface and two or more sides defining side edges, the upper surface having a plurality of projections extending upward there from in a tactilely detectable pattern; and, b. two or more cross beams attached to the lower surface of the tile member and projecting downward a distance there from, the distance defining a depth of the cross beams, each cross beam comprising a sidewall having two opposing ends which define a length there between, the sidewall being shaped so as to define a hollow channel extending the length and an opening at each end, the channel being in communication with an exterior via the openings; whereby air and the concrete or asphalt are displaced around and into the openings of the cross beams and toward the lower surface and two or more sides of the tile member as the embedment tile is embedded therein, leaving exposed the tactilely-detectable pattern of projections on the upper surface.
 2. The embedment tile of claim 1, wherein the projections are shaped and patterned so as to be compliant with the Americans with Disabilities Act Accessibility Guidelines.
 3. The embedment tile of claim 1, wherein the tile member is comprised of stainless steel.
 4. The embedment tile of claim 1, wherein the upper surface of the tile member is skid-resistant.
 5. The embedment tile of claim 1, further comprising two or more support members, each support member being attached to the lower surface of the tile member and projecting downward a distance there from, the distance defining a depth greater than that of the two or more cross beams and comprising a sidewall having two opposing ends which define a length there between, the sidewall being shaped so as to define a hollow channel extending the length and an opening at each end, the channel being in communication with the exterior via the openings, whereby the concrete is displaced around and into the openings of the support members as the embedment tile is embedded therein.
 6. The embedment tile of claim 5, wherein the depth of the two or more support members is sufficient to support the tile member at a surface height of the concrete during installation of the embedment tile therein.
 7. An embedment tile for producing a tactilely detectable surface in concrete or asphalt, comprising: a. a tile member substantially planar in form, having an upper surface and a lower surface and two or more sides defining side edges, the upper surface having a plurality of projections extending upward there from in a tactilely detectable pattern; and, b. two or more cross beams attached to the lower surface of the tile member and projecting downward a distance there from, the distance defining a depth of the cross beams, each cross beam comprising a sidewall having two opposing ends which define a length there between, the sidewall being shaped so as to define a hollow channel extending the length and an opening at each end, the sidewall further comprising two or more apertures therein, the channel being in communication with an exterior along the length via the two or more apertures and at each end via the openings; whereby air and the concrete or asphalt are displaced around and into the apertures and openings of the cross beams and toward the lower surface and two or more sides of the tile member as the embedment tile is embedded therein, leaving exposed the tactilely-detectable pattern of projections on the upper surface.
 8. The embedment tile of claim 7, wherein the projections are shaped and patterned so as to be compliant with the Americans with Disabilities Act Accessibility Guidelines.
 9. The embedment tile of claim 7, wherein the tile member is comprised of stainless steel.
 10. The embedment tile of claim 7, wherein the upper surface of the tile member is skid-resistant.
 11. The embedment tile of claim 7, further comprising two or more support members, each support member being attached to the lower surface of the tile member and projecting downward a distance there from, the distance defining a depth greater than that of the two or more cross beams and comprising a sidewall having two opposing ends which define a length there between, the sidewall being shaped so as to define a hollow channel extending the length and an opening at each end, the channel being in communication with the exterior via the openings, whereby the concrete is displaced around and into the openings of the support members as the embedment tile is embedded therein.
 12. The embedment tile of claim 11, wherein the depth of the two or more support members is sufficient to support the tile member at a surface height of the concrete during installation of the embedment tile therein.
 13. Method for producing a tactilely detectable surface in concrete, comprising: a. providing an embedment tile comprising: i. a tile member substantially planar in form, having an upper surface and a lower surface and two or more sides defining side edges, the upper surface having a plurality of projections extending upward there from in a tactilely detectable pattern; and, ii. two or more cross beams attached to the lower surface of the tile member and projecting downward a distance there from, the distance defining a depth of the cross beams, each cross beam comprising a sidewall having two opposing ends which define a length there between, the sidewall being shaped so as to define a hollow channel extending the length and an opening at each end, the channel being in communication with an exterior at each end via the openings; b. lowering the embedment tile into the concrete; and, c. positioning the upper surface of the tile member relative to a surface of the surrounding concrete as desired and so that the upper surface's tactilely-detectable pattern of projections is exposed.
 14. The method of claim 13, further comprising finishing around the two or more edges of the embedment tile.
 15. The method of claims 13, wherein the embedment tile's crossbeam sidewall further comprises two or more apertures therein, the crossbeam channel being further in communication with the exterior along the length via the two or more apertures.
 16. The method of claim 13, wherein the embedment tile's tile member is comprised of stainless steel.
 17. The method of claim 13, wherein the embedment tile, further comprises two or more support members, each support member being attached to the lower surface of the tile member and projecting downward a distance there from, the distance defining a depth greater than that of the two or more cross beams and comprising a sidewall having two opposing ends which define a length there between, the sidewall being shaped so as to define a hollow channel extending the length and an opening at each end, the channel being in communication with the exterior via the openings, whereby the concrete is displaced around and into the openings of the support members as the embedment tile is lowered into the concrete.
 18. Method for producing a tactilely detectable surface in concrete, comprising: a. providing an embedment tile comprising: i. a tile member substantially planar in form, having an upper surface and a lower surface and two or more sides defining side edges, the upper surface having a plurality of projections extending upward there from in a tactilely detectable pattern; ii. two or more cross beams attached to the lower surface of the tile member and projecting downward a distance there from, the distance defining a depth of the cross beams, each cross beam comprising a sidewall having two opposing ends which define a length there between, the sidewall being shaped so as to define a hollow channel extending the length and an opening at each end, the channel being in communication with an exterior at each end via the openings; and, b. securing the embedment tile in place; c. adjusting the embedment tile to meet slope or grade requirements; and, d. pouring the concrete onto the sub-base and under and around the embedment tile.
 19. The method of claims 18, wherein the embedment tile's crossbeam sidewall further comprises two or more apertures therein, the crossbeam channel being further in communication with the exterior along the length via the two or more apertures.
 20. The method of claim 18, wherein the embedment tile's tile member is comprised of stainless steel.
 21. The method of claim 18, further comprising two or more support members, each support member being attached to the lower surface of the tile member and projecting downward a distance there from, the distance defining a depth greater than that of the two or more cross beams and comprising a sidewall having two opposing ends which define a length there between, the sidewall being shaped so as to define a hollow channel extending the length and an opening at each end, the channel being in communication with the exterior via the openings. 